Composition for densifying porous masses and structures



r06. COMPOSlTlONS,

comma 0R PLASTlC 9 8 Patented Mar. 1943 i suchas concrete an n g such structures with; material so as to render them serviceable as'j re' gards strength o e and so as to re I em resistant to the action 'of 'frost' L The present" invention relates to v Cross Reference I I COMPOSITION FOR DENSIFYING "I 1 S NP UQ L I V, S.Wertz, Shaker Heights; Ohio No Drawing". Application llune 20,1939, SerialNo.280,1 '4 1 7 r 11 am; a compesi-' tion'of fluid material with solids in suspension,

which, under the action of pressure, may

forced into the void spaces of porous matei I this and to the action of'corrosive waters. 1 It is an object of this invention to provide improved composition which 'may be readily made to flow under pressure for long-distances through small channels 'in porous or honeycombed materials such' as concrete or masonry structures, which will harden without apprecia ble shrinkage,- and which, when hardened, will possess properties of rigidity, strength and im--' permeability equal to that of structuresmade' i es.

from Portland cement mortar or concrete under the most favorable-conditions. Another object of this invention is to A I I substantially fill all void spaces within the mass w His a matter of common observation them unsuitable for the services they were degardless of the cause, the imperfections take the form of cracks, crevices, honeycomb, and a general lack of density and solidarity, rendering the structure deficient as regards-,water-tighb:

nessand strength.

In the past, attempts have been made to repair such structures by drilling holes to theinterior and forcing into these holes a thin mor-' ,tar', slurry, or grout, comprising a mixture of A f-Portland cement and water. The examination o'fcores-taEen from structuresthus treated has disclosed that this method of repair is inefiective infilling the smaller voids, that such mixtures can be forced only for very short distances through small channelsbefore plug n occurs,

provide 1 a process of densifying and solidifying concreteand masonry structures which comprises forcme; under pressure, a fluid composition throughchannels, crevices, cracks and the like, so as to that I many concrete and masonry structures, such as H dams,-- brirmes, walls, tunnel linings, and the like,

exhibit internal imperfections which render" 85s signed to perform. These imperfections are due and that in larger voids there occurs a settlemenu of the cement, and a consequent rise of water. to the top of the void space before harden-1 ing, and a shrinkage of the volume of slurry as;-

setting and hardening takes place, as a conseduence of which the material within the void space is lacking in homogeneity, the space is ini completely filled with hardenedcement paste,

and thereis a lack of bond or adhesion between the'hardened paste and the concrete or stone 1 surrounding the void. j It is,'th erefore, an object of this invention to provide an improvedcomposition for densifying and solidifying 'concrete structures which will readily flow under-pressure into the voids-and cracks 01 a porous or; honeyc'ombed concretemasm. w. r

" Another object of this invention is to" provide j a suitable composition which will have highcrete structure, in which the cement and other e which, when set" or hard, has comparable to a: variety of causes, such as poor workman-f ship'at the time the structure was built, to the dissolution of soluble compounds by percolating waters, and to the disruptive action of frost. Re- I flowability, to minimize pressure losses due to friction, which can be easily forced into the con solid materials remain uniformly distributed'i'n the mix funtil solidification takes place, which will have very little shrinkage upon; setting, and

strength with the surrounding structure w l Another object of this invention is to provide a process of densifying andlsolidifying concrete v structures wherein the voids, cracks, crevices,- and the like, maybe substantially filled without; separation of 'the material, and the composition may be set and firmly adhere to'theexisting' concrete structure." 1 j F When large dams are constructed it has frequentlyT been found that deleterious seepage around the dam frequently occurs to adepth of 100 or 200 feet'below its base. I To reduce this pressure, such as 1000 lbs. per sq. in., a very thin,

" watery slurry of Portland cement into the earth at the base of the dam. This thin slurry is then followedwith a thicker material to solidify the Ze t v The'high pres'sure initially used causes relatively large channels to open in the direction of least resistance toflow, and the solidifying material which is later forced into the opening fo l-' lows these channels without entering the great; mass of voids. The desired solidification of the dan i foundation; is, therefore} not obtainedJ- -"It is, therefore, an important object of invention to providea process and composition. for densifYi lS earth, gravel, and rock stratar 'wherein the voids are filled, in order -to render them more suitable for foundations of dams,

buildirms, and the like.

It has been found that the tendency of Portland cement slurries to plug channels many times the size of the largest cement grains is due to several causes, among which are the flocculation or agglomeration of small particles of cement to form clusters or clumps, the rapid hydration of the smaller particles of cement to form a viscous gel, the particle interference or frictional resistance to the sliding of one .particle over another, and the lack of water-retaining capacity of the slurry. This latter property is commonly referred to as bleeding.

All Portland cements contain compounds of lime, silica, iron, and aluminum. When water is added to Portland cement, hydration begins, and during the early stages of hydration, known as "setting," precipitation of aluminum and calcium hydroxide occurs to some extent. The charge of the metallic cations ofthese precipitated hydroxides is positive, while the charge on the unhydrated basic cement particles .is negative. There is, therefore, a natural tendency in Portland cement for the precipitated hydroxide to cause flocculation of th suspended cement particles.

Since the concentration of aluminum ions is for the first few hours relatively larger than that of other compounds, and since, in the compounds of aluminum, the metallic ions are relatively highly charged, the aluminum may be considered as the most powerful factor in causing agglomeration of the cement particles in a slurry.

Aluminum hydroxide or the hydrous oxide of aluminum is very hydrcphilic, rapidly combining with large quantities of water to form a viscous gel which produces great increases in viscosity or decrease in the mobility of the slurry. This phenomenon is commonly referred to as the setting nt. v

I have found that the formation of the gels,

r the early stiffening of the slurry, may be materially retarded by adding a quantity of acidic colloidal silica or ozzolanic material. Being E 45 a finely Hivid'ed state, the particles also act to physically separate and to maintain in suspension the particles of cement, and to prevent the agglomeration of e cement-grains. The pozzolana or finely divided siliceous materials thus act under certainponditions as a protective colloid.

The acidic colloidal silic or co 01 a1 material which reduces some silicic scam meme complex mineral silicates, such as are present in as urnace 55 S 8. and certain natural si ceo e- 571's generally classified as gzzola'na, forming compounds having consi era le cementitious value with the lime that may be liberated as a byproduct during the setting of the cement.

Some types of blast furnace slag are hydraulically active in themselves and are very desirable.

In addition to retarding the-formation of the gel, such silicates are advantageous, in that the acidic colloidal silica in these materials slowly combines with the actiye calcium hydroxide l"-calciui'n sisters the contributes to both strength and t e impermeability of the hardened cement'compo-. sition. Moreover, such materials act as fillers 70 and reduce the volumetric shrinkage that takes place during the setting or hardening of the slurry.-

A Portland cement slurry containing a filler 75 that is pozzolanic or that has acidic colloidal Agents that are generally satisfactory for plasticizing and lubricating the cement slurry are oleaginous materials, including fatty acid 1 cerides, the fatty acids themselves, an sa ts an es't'ers'thereof, and, in particu ar, the stearates class may pears that the liberation o and oleates. Although a number of agen o solublesoaps withlme, it anmix is so slow that only a very small amount of such insoluble soaps would be formed duringthe placement of the cement slurry. The esters and salts of the fatty acids apparently, however, hydrolize in the aqueous mixture so that the fatty acid constituent assists in forming and maintaining the suspension of the solids and also provides lubrication between the particles.

Other agents may be used to aid in maintaining a stable suspension and to assist fiow of the cement slurry including the solids of the pozzolanic type. Some of them are powerful in forming the suspension and a very small quantity is required; others are more important to maintain the solid materials in suspended condition. Such agents generally have an adverse eflect on the strength of the hardened cement composition when used in substantial quantities. However, with'small amounts, a substantial increase in the stability of the slurry may be obtained without a substantial decrease in strength. Agents of wetT 1 g'agents, as the this type include stabilizing agents, such as the al inates, gelatin, glue, casein, tragacanth, and the like. Th

bentggjtes, m e more powerlfil alkylated sulphonatg aromatic compounds an sa ts thereof, or compounds whic are obtained Ty condensing formaldehyde with a polynuclear aromatic s lfo c ignm su omc acids gerivatives thereoi may be used, but they should be used in very small quantities.

The quantity of agent to be added to the slurry depends upon the type used. The agent that are generally satisfactory for plasticizing and lubricating the cement slurry, such as the oleaginous materials, and particularly the alkali stearates and o eates, may be used advantageously in Tfifiitities'uFtB'l% or 2% by weight of the Portland cement. However, when agents of the tting o u if in t higher alcohols,

e such as the gem a y g yp sul honates, I sulEhonlc acid derivatives, etc m entioned-aBove, w on 0 not generally precipiis usually preferred.

The quantity of finely divided silicious material or acidic colloidal silica used will depend upon the character and qualities desired in the resulting slurry and hardened cement. silicious material and Portland cement may be usedadvantageously in a ou Depending up n the type..of

Usually the We? cious .material used and the properties desired in the slurry, the above proportion can be varied considerably.

lOfi. COMPOSlTlONS,

kali salt of stearic aci of stearate per sacr'fo cement. Good" results 4 in the surface of the concrete or masonry mass comma 0R PLA amount twice that of the Portland cement.

When using water-quenched blast furnace slag,

Cross Reference the finel y ground blast furnace slag, shale, etc.,' which aid in forming and maintaining a stable suspension by acting as protective colloids for the cement as well as tending to retard the geloptimum results are usually obtained when the 5 lation of the cement. By varying the proporproportion of slag to cement is 1:1 011 /221- The fluidity or the ability of a cement mixture to; be pumped through fine openings without clogging them is increased by the addition of tions of the ingredients and using care in the selection of them, a. cement slurry can be made protective colloids, such as the alginates, gela- 10 until the material hasjbeen forced into the finest tin, glue, ca s e i n, bentonites, gum tragacanth, aTnTt'Hlike, which have a sta 112mg e e the mixture, permitting the pro uc on o more stable suspension having relatively high fluidity.

The use of the hereinbefore mentioned materials I5 the presence of cracks, cavities, and large or' containing agiglio lgllgig l silica, such as finely ground 's'hales, blast furn ace slag, etc, is preferred, since, in a ddition to theiF' action as pr otective colloids in maintaining the stability of being solidified. 1 1 I It'has' been found that a concrete or masonry structure which is internally defective as regards cracks and'interstices of the structure or 'mass small void spaces in general, may be economically and efficiently repaired so that it is substantially free from such imperfections by the use'of properly proportioned mixtures of Portland cement,"

the slurry, they retard the set andprovide some 2'0 chemically active, finely divided siliciousj at:

additional strength in the hardened material.

A very small percentage of one of the more pow- "Elf'h as those previously mentione oge eiwfth water sufficient to produce a slurry, grout, or paste of the required consistency. The composition'ma'y be forced for long distances through voids and channels with a minimum of fric-' tional resistance. It will retain its fluidity and mobility for an hour or more, and the solids will c'ellent results have been achievedwith'a mixture: remain in suspension without tendency towards which has been pfilveri'zedto a sufi cient m eness to pass through a. 100-mesh screen, and which has a surface area of at least about 2,200 sq. cm. .per to its surroundings, and is of high tensile and gram. To this mixture there is added 12 to 15 gallons of water per sackof cement and a sufficient quantity of an emulsion containing an al- 0 urnis to 2 s.

have been achieved by using equal'parts of Pgrte land cement and fly ash of low carbon conten for W505 the fineness, as measured n ermsof surface area, has varied from cm.ormore per gram.

A suitable quantity cf an chemically active silicious material of volcanicdr'diatomaceous origin, such as volcanic ash, tufi diatomaceousv earthand shale, or other m'afe fial having sim -j ilar properties, may hg substituted for masking ,g'dsticea-voids, fissures, etc., in the region of the mace slag withgoocr'res s l e a ve exconcrete or masonry adjacent the holes. The

a mple. These materials may be either added. to the cement clinker and round with the cementor separately added We n a -While any commercial Portland -cement can be employed, it has been found that best results are achieved with a cement that is fairly low in the compound tricalcium am of suc eness a e sur ace area will be in the neighborhood of 1,690 to 1,800 or more sq. cm. per gram with all particles passing a screen of 100 meshes to the inch and a relatively small percentage of particles having a mean diameter of less than 5 microns. It will thus be seen that the' cement slurry should have included in its ingredients, in addition to the cement and water, ingredients which have the properties of forming and maintaining. a stable suspension of the solids in the water, retarding the set of the cement, and lubricating Ming the flowability of the slurry r vol s an n rs ces "or-5; structure or mass.

i Certain of the ingredients of the slurry may perform more than one of these functions such as flocculation or agglomeration, or'without appre-' ciable settlement. The composition hardens without appreciable shrinkage or water gain, and, when hardened, isimperviou's, tenaciously bonds compressive strength.

Briefly, an illustration of the process of repair isasfollows: W

A plurality of holes are formed, as by drilling,

to a predetermined level, and according to a predetermined pattern. The holes may be washed with water to flush out loose materials from the voids and pockets of the porous interior of the concrete or masonry mass, and air under pressure-may be supplied to the holes to displace the water or other washing liquid.

The composition is next supplied to the holes under-pressure to force it into all the inter- -under pressure for a period oftime before the 60, is of such a thickness that the voids and interstices cannot be thoroughly filled at the depth level of the holes, the holes may be drilled to a further depth level through a portion of the structure just treated, where the process steps two or three feet, and thecomposition may be or under supplied. to the holes by air pressure,

Examin densified and solidified, it maybe desirable that the surface of the structure be treated by a process which will render it impervious, so that deleterious substances, such as moisture, cannot gain access to the interior of the structure and cause deterioration or disintegration thereof. Such a process is one in which a suitable weatherproofing composition is applied to the surface of the-structure in any suitable manner and is thoroughly worked into the surface. It has been found that when a weather-proofing composition is applied under pressure, and simultaneously worked into the concrete by means of an abrasive, as an annular power-driven carborundum wheel, all surface projections are removed and all surface voids are filled, thereby providing a structure having a smooth surface of uniform color which is, in itself, dense and durable to an appreciable thickness.

nthe "Ill s 'ata, such as are present at dam and building stes, a properly proportioned mixture of Portland cement, chemically active, finely divided silicious materials such as those previously named, suflicient water to make a slurry, and

preferably with one or more of the above mentioned plasticizing or lubricating agents is used in the same manner as in the case of the solidification of other porous structures such as con- 500 or 1000 lbs. per square inch. Usually a pres sure of about 300 or 400 lbs, per square inch is used, and the pressure is maintained on the cement for a considerable time toallow it to fiow into the smaller voids as well as the larger ones and to allow the slurry to set under pressure. After solidifying the material at one level, holes may be drilled through the solidified material to a greater depth, etc until the foundation material is solidified to a depth of 200 or 300 feet if desired. Because the pressure used' is usually insufiicient to open a channel in the foundation, and because the mixture used does not'readily clog the voids, the desired solidification of voids of all sizes occurs. .I

through voids and interstices of a masonry or concrete structure.

2. A slurry for filling the voids and interstices of porous masses of earth, rock, masonry, concrete and the like, which comprises Portland cement, a lubricating material, a finely divided filling material containing acidic colloidal silica in suspension, and a protective colloid, said finely divided filling material being present in said slurry in an amount from about one to two times the amount of the cement by weight, said lubricating material being present in an amount up to about 2% of the weight of the cement, all the materials of said slurry being sufiiciently fine to pass through a IOU-mesh screen.

3. A composition for filling the fine voids and interstices of porous masses of earth, rock, masonry, concrete and the like, comprising a finely divided filling material containing sufficient acidic colloidal silica toretard gellation of the composition, Portland cement, water, and a relatively small amount of at least one plasticizing and lubricating material to maintain the filler and cement in suspension and to increase fiowability, said composition being characterized by its ability to flow under pressure prises 'a material containing acidic colloidal silica, Portland cement," and a relatively small amount of lubricating agent, said material being present .in' an amount of from about one- This invention is" a continuation in part of l application .Serial No. 194,933, filed March 9,

1938. It is to be understood that the particular form of the invention shown and described, and the particular procedure set forth, are presented for purposes of explanation and illustration, and that various modifications may be made without departing from the spirit of my invention. What I claim is: v

1. A slurry for filling the fine voids and m terstices of porous masses of earth, rock mason ry, concreteand the like, comprising Portland cement and a filler having suflicient acidic col loidal silica to retard the gelling of the cement,

a relatively small amount of a lubricating and half to' about twice the amount of the cement by weight, said composition when mixed. with water forming a homogeneous, stable suspension having high fiowability and plasticity, to permit its penetration through fine voids and interstices of a porous mass.v i

.5. A highly fiowable and plastic composition which comprises an aqueous'Portland cement' slurry having incorporated therein a filling material containing acidic colloidal sil' and a relatively small amount 1n proportion to the weight of the cement and filling material of an oleaginous material, said filling material being present in an amount by weight of more than approximately half the weight of the cement, said oleaginous material being present in an amount up to 2% .of the weight of the cement, said composition being in the form of a stable, homogeneous suspension, containing no ingredients subversive to high fiowability, and being characterized by its high capacity to penetratefor relatively great distances through fine voids and interstices.

6. The process of increasing the plasticity and is capable of penetration through fine voids and v interstices without separation or settlingj 7. A composition for filling fine voids and in terstices of porous masses of earth, rock masonry, concrete and the like," comprising Portland cement, a filler containing substantial amounts of acidic colloidal silica to retard the gellation laimPerms? comma OR PLASTlC of the cement and a lubricating agent, said filling material being present in an amount of about one-half to about twice the amount of the weight of the cement, said lubricating agent being present in an amount up to about 2% of the weight of the cement, said composition containing no ingredients subversive to high fiowability and when mixed with water being capable of flowing under pressure through small voids and interstices without separation or settling,

8. A composition for filling fine voids and interstices of porous masses of earth, rock, masonry, concrete and the like, comprising Portland cement, a finely divided, chemically active siliceous material containing substantial amounts 'of acidic colloidal silica to retard the gellation of the cement and a lubricating agent, said fill- Cross Reference ing material being present in an amount of about one-half to about twice the amount of the weight of the cement, said lubricating agent being present in an amount up to about 2% of the the amount of the weight of the cement, an oleaginous material in an amount up to about 2% of the weight of the cement, said composition containing no ingredients subversive to high fiowability and when mixed with water being capable of flowing under pressure through small voids and interstices without separation or settling.

10. A composition for filling fine voids and interstices of porous masses of earth, rock, masonry, concrete and the like, comprising Portland cement, finely ground, water-quenched blast furnace slag in an amount equal to from one to one and one-half times the weight of the cement and ammonium stearate in an amount up to about 2% of the weight of the cement, said composition containing no ingredients which prevent fiowability through fine passageways.

11. A composition for filling fine voids and in- 0 terstices of porous masses of earth, rock, mason- Weight of the cement, said composition containry, concrete and the like, comprising finely divided Portland cement, a finely divided filler in amounts of one-half to twice the amount of the cement, and containing substantial amounts of acidic colloidal silica to retard the gelation of the cement, and an oleaginous material in an amount up to 2% of the weight of the cement to increase fiowability of the composition, all ingredients of said composition being finely divided so that when mixed with water the material is capable of flowing under pressure through fine voids and interstices without separation or settling.

LOUIS S. WERTZ.

Examine 

